Cap for a tubular sleeve for a concrete structure

ABSTRACT

A cap for a tubular sleeve having a cylindrical wall extending along a longitudinal axis for forming a passage through a concrete structure. The sleeve has radially extending ridges separated into segments with a channel parallel to the longitudinal axis. The channel has a circumferential width W. The ridges spaced apart a distance Z along the longitudinal axis. The sleeve having an inner diameter D. The cap has a cap element and a positioning tab. The cap element has a circular outer periphery with a flat top surface and a flange having a bottom end, and the tab extends inwardly from the bottom end and has a bottom surface that is orthogonal to the longitudinal axis. The tab has an inner surface that is inclined at an acute angle to the bottom surface. The tab has a width smaller than W and an axial length smaller than Z.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is divisional application of and claims priority toU.S. Non-Provisional patent application Ser. No. 16/224,609 filed onDec. 18, 2018, Provisional Patent Application No. 62/657,519 filed onApr. 13, 2018, and Provisional Patent Application No. 62/609,215 filedon Dec. 21, 2017, the entire contents of which are incorporated hereinby reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not applicable.

BACKGROUND

An extendable tubular sleeve for poured concrete structures, such asslabs, floors and decks, is described in U.S. Pat. Nos. 9,086,174 and9,103,116. But that extendable sleeve uses a vertically-split base toconnect to a metal frame that supports intumescent rings and thatvertically-split base is cumbersome to assemble as it requires threadedfasteners to hold the parts securely together and it allows verticalmisalignment of the vertically split parts of the base. Moreover, aflexible diaphragm is clamped between a top of the base and a sleevethat is threaded onto the base and the threading rotation of the sleevecan damage the flexible diaphragm and can also distort the diaphragm,thereby degrading the diaphragm performance and sealing with the pipepassing through the sleeve and diaphragm during use. For the above andother reasons, there is a need for an improved extendable sleeve that isfaster and easier to assemble and that does not damage the diaphragmseal during use.

The extendable inner tubular sleeve is adjusted in length by cutting theinner tubular sleeve to length and then putting on a cap to preventconcrete from entering the sleeve as the sleeve is entrained inconcrete. But cutting the sleeve to length is time consuming, inaccurateand cumbersome. There is thus a need for an improved extendable sleevethat is easier to adjust in length.

Floor drain fittings are typically supported independently of theextendable sleeves that form the bulk of the fluid passage throughconcrete surfaces. This independent support is used because the floordrain fittings are very heavy and require sufficiently preciseorientation and location that the extendable sleeves are not used tosupport the fittings. There is thus a need for an extendable sleeve thatcan be connected to and support a fitting, such as floor drain fitting,for a poured concrete structure.

BRIEF SUMMARY

An improved cap and assembly is provided for a poured concretestructure, such as deck or slab. The improved assembly has a diaphragmseal over-molded to a top plate having a depending sidewall that issnap-fit to a base containing a fire ring. A tubular sleeve is connectedto the over-molded top plate by snap fit connections to the sidewall andby threaded fasteners passing through sockets in the sleeve, sidewalland base. The over-molded diaphragm has a funnel shape. A first sleevecap has depending positioning tabs that may be broken off to adjust thecap height relative to the sleeve, with an inwardly extending latchingsurface engaging the sleeve when the tabs are removed. A second cap hasinwardly extending tabs that fit into channels on the sleeve fit betweenridges on the sleeve when rotated to adjustably position the second capon the sleeve.

There is also advantageously provided in improved cap for a tubularsleeve having a cylindrical wall extending along a longitudinal axis forforming a passage through a poured concrete structure. The tubularsleeve has a plurality of radially extending ridges separated intosegments with a channel parallel to the longitudinal axis separatingeach segment. The channel has a circumferential width W with the ridgesspaced apart a predetermined distance Z along the longitudinal axis andthe tubular sleeve has an inner diameter D. The improved cap has a capelement having a circular outer periphery with a generally flat topsurface and a flange depending from the outer periphery of the cap andencircling the periphery of the cap element. The flange has a bottomend. The cap has at least one positioning tab extending inwardly fromthat bottom end of the depending flange. The positioning tab has abottom surface that is orthogonal to the longitudinal axis during useand also has an inner surface that is inclined at an acute angle to thebottom surface so the inner surface faces toward an underside of the capelement and toward the longitudinal axis. The positioning tab isadvantageously curved and has the same curvature as the dependingflange. The positioning tab may further have a width in thecircumferential direction which width is smaller than W and also has anaxial length which length is smaller than Z so the positioning tab mayfit between two ridges of the sleeve and slide axially off any ridgeengaged by the inclined surface.

In further variations, the width of the positioning tab may be about Wand the length may be about Z. Optionally, there are between two and sixpositioning tabs equally spaced about a circumference of the flange,with three or four positioning tabs preferred. The cap may also have aninner, depending cylindrical flange having an outer diameter about D butslightly smaller than diameter D of the sleeve so the inner flange fitsinside the wall forming the tubular sleeve. The cap thus mayadvantageously have the diameter of the inner, depending cylindricalflange be about D but slightly smaller than diameter D for a snug fitwith the cylindrical sleeve.

There is also provided a second cap for a tubular sleeve having acylindrical wall extending along a longitudinal axis for forming apassage through a poured concrete structure. The tubular sleeve has aplurality of radially extending ridges, with a first of the plurality ofridges located an axial distance d from a distal end of the tubularsleeve that is closest to the first of the plurality ridges. The secondcap has a circular periphery with a cylindrical, depending flange at theperiphery and extending along the longitudinal axis during use. Thedepending flange has external threads thereon to engage extension tubesor other parts. The cap has a generally flat top surface to avoidexcessive entrainment in concrete and avoid catching on concretefinishing tools. The second cap may also have at least two curvedposition stops depending from a bottom end of the depending flange inorder to position the second cap a pre-determined distance above anabutting ridge or flange on the mating sleeve. The second capadvantageously has the depending flange connected to each position stopby a weakened area extending along the curvature of each position stopto make it easier to break off the position stop from the dependingflange and thus lower the height of the cap by the axial length of theposition stop. Each of the at least two position stops have the sameaxial length. The second cap advantageously has a lip on the inside ofthe depending flange and extending inward and located opposite theexternal threads. The lip may have an inclined bottom end facingdownward and toward the longitudinal axis so as to more easily fit ontoan outwardly extending flange. The lip has a flat surface opposite theinclined surface which flat surface is generally orthogonal to thelongitudinal axis to form a catch with an outwardly extending flange.The flat surface is advantageously located an axial distance slightlygreater than the distance d so the lip can engage the outwardlyextending ridge on the top of the sleeve in a snap-fit or snap-lockengagement.

In further variations, the second cap may have from two to six positionstops, each having an axial length of about 0.25 to about 1 inch andpreferably, but optionally, equally spaced about a circumference of thedepending flange. The cap may further include a plurality of wrenchingrecesses in the top surface of the cap.

There is advantageously provided a diaphragm seal assembly for use witha base connected to a tubular sleeve having a cylindrical wall with aninternal diameter D. The sleeve extends along a longitudinal axis forforming a passage through a poured concrete structure. The assembly hasa flexible diaphragm seal with a circular opening on the longitudinalaxis sized to allow passage of an elongated member while flexiblyengaging an outer surface of that elongated member. The diaphragm sealassembly includes an annular seal housing having a sidewall extendingalong and encircling the longitudinal axis and having an annular topplate extending inward toward the longitudinal axis with a centralopening at the axis that is larger in diameter than the circular openingof the diaphragm seal. The top plate has a surface which is textured andwhich encircles the longitudinal axis. The flexible diaphragm seal hasan inner diameter defining the circular opening and also has anover-molded outer diameter that extends over the textured surface andaround the longitudinal axis so that textured surface and top plate areconnected to the flexible diaphragm by over molding that outer diameterto that textured surface. This provides a unitary connection of the sealto the seal housing rather than a clamped assembly as in the prior art.

In other variations, the diaphragm seal assembly has the texturedsurface on a top surface of the top plate, although the textured surfacecould be on the bottom of the top slate with the flexible seal extendingthrough the central opening of the top plate. The top surface and topplate advantageously extend radially inward, but could be inclinedupward or downward.

The flexible diaphragm may have a funnel shape extending out of a planeorthogonal to the longitudinal axis through the textured surface whenthe diaphragm is in an undeformed condition, with the top plate inclinedupward or downward, or with the top plate in a plane orthogonal to thelongitudinal axis. The funnel shape may have straight walls forming afrusto-conical shape between the top plate and the inner diameter of thediaphragm. The frusto-conical shape may advantageously extend toward adistal end of the tubular sleeve during use. The funnel shape may havecurved walls. The curved walls may extend toward a distal end of thetubular sleeve during use.

The diaphragm seal assembly may have the seal housing sidewall extendsin an axial direction opposite the funnel shape, or extend in the samedirection as the funnel shape. The seal housing sidewall may have aplurality of latch members extending parallel to the longitudinal axisin a direction away from direction in which the flexible diaphragmextends. The seal housing sidewall may be connected to a base extendingalong the longitudinal axis and enclosing a fire ring of intumescentmaterial that encircles the longitudinal axis. The seal housing sidewallmay also be connected to the base by a plurality of snap-lockconnections. The snap-lock connections may include elongated latchmembers having barbed ends to engage catches in recesses on the basebeing preferred to connect the parts. But other male-female connectionscan be used. The assembly may also include a plurality of threadedfasteners connecting the seal housing sidewall to the base. The assemblymay include the tubular sleeve, with a plurality of threaded fastenersextending between the tubular sleeve and the base. The assemblyadvantageously includes the tubular sleeve, with the tubular sleeve,seal housing sidewall and base each having a socket, and with aplurality of threaded fasteners extending through the sockets to connectthe tubular sleeve, seal housing sidewall and base together.

Advantageously, the textured surface comprises a plurality of concentricgrooves. Further, a top surface of the over-molded outer diameter mayhave a plurality of generally concentric grooves, axially opposite thetextured surface. Advantageously, the assembly includes the sleeve and abottom of the sleeve is textured, preferably with concentric ridges,which textured sleeve bottom abuts the over-molded outer diameter of thetop plate.

There is also advantageously provided an assembly for forming a passageextending along a longitudinal axis through a poured concrete structureformed on a support surface and having an exterior concrete surface. Theassembly advantageously includes a base containing a fire ringencircling the longitudinal axis where the base has at least onefastener hole to connect the base to the support during use. A tubularsleeve having a bottom is connected to the base to form at least aportion of the passage through the concrete structure during use. Thesleeve has a top end with a first outer diameter D1. A floor fitting isconnected to the sleeve. The floor fitting has a top flange extendingaway from the longitudinal axis and a bottom floor fitting tube with anouter diameter D2. The floor fitting has a center of gravitysubstantially centered on the longitudinal axis. A no-hub connectorconnects the sleeve to the floor fitting. The no-hub connector includesa tubular body having opposing top and bottom tubular body ends whichare resiliently compressible. The bottom floor fitting tube extendsinside the top tubular body end and the top end of the sleeve extendsinside the bottom tubular body end to provide a fluid connection. A topring clamp encircles the tubular body and compresses the top tubularbody end against the bottom floor fitting tube. A bottom ring clampencircles the tubular body and compresses the bottom tubular body endagainst the end of the sleeve. The ring clamps are typically hose clampsor other adjustable length, clamping fasteners. The base, sleeve andno-hub connector are self-supporting of the floor fitting so the floorfitting top flange is substantially perpendicular to the longitudinalaxis, without the use of any braces, wires or support struts extendingbetween the support on which the concrete is poured and the base, sleeveand no-hub connector.

In further variations, the assembly may include a first threadedfastener connecting the sleeve, top base and bottom base together alonga first threaded fastener axis, and optionally connecting those parts tothe support. The assembly may also include a second threaded fastenerconnecting the sleeve, top base and bottom base together along a secondthreaded axis, and preferably further connecting those parts to thesupport onto which the concrete is poured to form the structure.

In still further variations on this assembly, the tubular body isadvantageously about 4 to about 8, and more preferably about 4 to 6inches long. A stiffening sheath may be interposed between the ringclamp and the tubular body and encircling the tubular body.Advantageously, diameters D1 and D2 differ by no more than about 10%.Preferably, a single tubular sleeve extends between the base and theno-hub connector, but for thicker concrete structures the tubular sleevemay include a first tubular sleeve connected to the base and a secondtubular sleeve connected to the no-hub connector, with the first andsecond sleeves being connected, preferably by threaded fasteners. Theassembly may include any or all of the base and diaphragm variationsdescribed herein, including an upper and lower base connected togetherby snap-fit connections, with the sleeve connected to the upper base bysnap-fit connections, or with the lower base is connected to a CD plateby at least one of a threaded fastener or a snap-fit connection.

The resulting concrete structure advantageously has the flangesubstantially parallel to and located at the exterior concrete surface,with no supporting struts or wires in the concrete connecting the sleeveor floor fitting to the support. The absence of these supporting orstabilizing structures provides for a more uniform concrete interlocksurrounding the passage through the concrete structure and avoidscrack-inducing and rust-inducing struts, wires and braces passing as oddangles through the concrete to various parts of the tubular passagethrough the concrete structure.

There is also advantageously provided a kit for forming a tubularpassage for poured concrete structures formed on a support surface. Thekit may include an upper base having a sidewall extending along andencircling a longitudinal axis and having an annular top plate extendinginward toward the longitudinal axis with a central opening centered onthat axis. The top plate advantageously has a textured surfaceencircling the longitudinal axis and an outer diameter of the topsurface. A flexible and elastic diaphragm seal has an inner diameterdefining a circular opening centered on the longitudinal axis andsmaller in diameter than the central opening in the top plate. Thediaphragm is connected to the top plate by over-molding an outerperiphery of the flexible diaphragm to that textured surface. The kitalso includes a lower base encircling the longitudinal axis and havingfastener openings to fasten the lower base to the support during use.The upper base and lower base may have a plurality of aligned snap-fitconnections to connect the lower base to the upper base during use. Thekit also advantageously includes a tubular sleeve extending along thelongitudinal axis during use. The tubular sleeve has a top end and abottom end. The upper housing sidewall and the bottom end of the sleeveeach have a plurality of aligned snap-fit connections to connect thesleeve to the upper base during use.

In further variations, the kit may include the various other partsdescribed herein. The kit may include, for example, a corrugated deckplate, with the lower base and corrugated deck plate having a pluralityof aligned snap-fit connections to connect the lower base to corrugateddeck plate during use. The kit may advantageously include a no-hubconnector and even a floor fitting. The no-hub connector may have adeformable tubular body with top and bottom opposing ends. A top and abottom ring clamp are included with or on the no-hub connector and eachring clamp is sized to encircle the respective top and bottom end of thetubular body during use. The bottom end of the tubular body is sized toenclose and be tightened against the top end of the sleeve by the bottomring clamp during use.

The kit may also have the tubular sleeve, upper base and lower baseprovided with a first socket which may be aligned along a first fasteneraxis, and each have a second socket which may be aligned along a secondfastener axis. The kit also advantageously includes a first threadedfastener having a length sufficient to pass through the first socketswhen they are aligned along the first fastener axis as well as includinga second threaded fastener having a length sufficient to pass throughthe second sockets when they are aligned along the second fastener axis.The fastener length is sufficient to extend beyond the sockets adistance sufficient to fasten those connected parts together or tofasten those connected parts to a CD plate or to the support onto whichconcrete is poured to form the concrete structure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other advantages and features of the invention will be betterappreciated in view of the following drawings and descriptions in whichlike numbers refer to like parts throughout, and in which:

FIG. 1 shows an exploded perspective view of an extendable sleeveassembly;

FIG. 2 shows a top view of the assembly of FIG. 1 ;

FIG. 3 shows a sectional view of the assembly of FIG. 1 , taken alongsection 3-3 of FIG. 2 ;

FIG. 4 shows an exploded perspective view of a fire ring and intumescentrings held within the fire ring;

FIG. 5 shows a top, perspective view of a lower base;

FIG. 6 shows a bottom perspective view of the lower base of FIG. 5 ;

FIG. 7 shows an exploded perspective view of the lower base and an upperbase and seal assembly;

FIG. 8A is a top view of an assembly of the lower and base, the upperbase seal assembly and an inner tubular sleeve;

FIG. 8B is a sectional view of the assembly of FIG. 8A, taken alongsection 8B-8B of FIG. 8A;

FIG. 8C is an enlarged portion of FIG. 8B, taken along section 8C-8C ofFIG. 8B,

FIG. 8D is an enlarged view of the lower right portion of FIG. 8B,showing a latch and catch connection between the upper base and sealassembly and the lower base assembly;

FIG. 9A is an upper perspective view of the upper base and seal assemblyand its flexible diaphragm;

FIG. 9B is a lower perspective view of the upper base and seal assemblyof FIG. 9A;

FIG. 9C is a side view of the upper base and seal assembly of FIG. 9A;

FIG. 9D is a top view of the upper base and seal assembly of FIG. 9C;

FIG. 9E is a bottom view of the upper base and seal assembly of FIG. 9C;

FIG. 10A is an upper perspective view of an inner tubular sleeve;

FIG. 10B is a lower perspective view of the inner tubular sleeve of FIG.10A;

FIG. 10C is a side view of the inner tubular sleeve of FIG. 10A;

FIG. 10D is a top view of the inner tubular sleeve of FIG. 10C;

FIG. 10E is a bottom view of the inner tubular sleeve of FIG. 10C;

FIG. 11A is a top view of a first safety cap on an outer sleeve andshowing a lower base;

FIG. 11B is a sectional view taken along 11B-11B of FIG. 11A showing afirst safety cap on an outer sleeve, an inner tubular sleeve, an upperbase and seal assembly, a lower base and an aerator box below the lowerbase;

FIG. 11C is an enlarged view taken from FIG. 11B, showing how the innertubular sleeve may seal against the diaphragm on the upper base and sealassembly;

FIG. 12A is a top view of an inner tubular sleeve on an upper base andseal assembly that is connected to a lower base;

FIG. 12B is a partial sectional view taken along section 12B-12B of FIG.12A;

FIG. 12C is an enlarged view of a portion of FIG. 12B, showing how theinner tubular sleeve may connect to the upper base and seal assembly;

FIG. 12D is a full sectional view taken along section 12D-12D of FIG.12A, showing a flange on the inner tubular sleeve resting on a stop onthe upper base and seal assembly;

FIG. 12E is an enlarged portion of FIG. 12D showing the flange on theinner tubular sleeve resting on a stop on the upper base and sealassembly;

FIG. 13A is an exploded perspective view of an assembly having anadapter to change diameter and extend the length of the extendablesleeve assembly and a cap on the adapter;

FIG. 13B is a top view of the assembly of FIG. 13A;

FIG. 13C is a section of the assembly of FIG. 13A, taken along section13C-13C of FIG. 13B;

FIG. 13D is an enlarged upper corner of FIG. 13C showing the capengaging the adapter;

FIG. 14A is an exploded perspective view of an assembly having a secondcap on the inner tubular sleeve;

FIG. 14B is a top view of the assembly of FIG. 14A;

FIG. 14C is a sectional view of the assembly of FIG. 14A, taken alongsection 14C-14C of FIG. 14B;

FIG. 14D is an enlarged upper corner of FIG. 13C showing the second capengaging the adapter;

FIG. 15A is an exploded perspective view showing the inner tubularsleeve and a short, larger diameter adapter;

FIG. 15B is a top view of the assembly of FIG. 15A;

FIG. 15C is a sectional view of the assembly of FIG. 15A taken alongsection 15C-15C of FIG. 15B;

FIG. 15D is an enlarged view of the connection between the short adapterand the inner tubular sleeve;

FIG. 16 is an exploded perspective view of the short adapter of FIG. 15Aon an outer sleeve;

FIG. 17 is an exploded perspective view of an assembly having a drainfitting, no-hub connector and an extendable sleeve assembly;

FIG. 18 is a perspective view of the assembly of FIG. 17 ;

FIG. 19A is a top view of the assembly of FIG. 18 ;

FIG. 19B is a sectional view of the assembly of FIG. 18 taken alongsection 19B-19B of FIG. 19A;

FIG. 20A is a top perspective view of a filament assembly;

FIG. 20B is a bottom perspective view of the filament assembly of FIG.20A;

FIG. 21A is a top view of an upper and lower base on a CD plate;

FIG. 21B is a partial sectional view taken along section 21B-21B of FIG.21A; and

FIG. 21C is an enlarged portion of FIG. 21B showing an interconnectionbetween the CD plate and lower base.

DETAILED DESCRIPTION

As used herein, the following part numbers refer to the following parts:20—extendable sleeve assembly; 22—CD plate; 24—opening in the CD plate;26—lower base 27—base threads; 28—lower base sockets; 30—catches inlower base; 32—fire ring; 34—intumescent members; 36—upper base and sealassembly; 38—ring tab; 40—fingers on ring; 42—flange; 44—latch; 46—upperbase sockets; 50—top plate; 52—inner flange; 54—flexible diaphragm;56—diaphragm sidewall; 58—indentations; 59—position stop; 60—innertubular sleeve; 62—base of inner tubular sleeve; 64—sleeve flange;70—first set of ridges; 72—second set of ridges; 74 a, 74 b—channels;76—end segments; 78—engaging protrusion on end segment 76; 80—whiskersupport; 81—whisker assembly; 82—whiskers; 84—whisker base; 86—malewhisker connector; 88—female whisker connector; 92—inner sleeve socket;94—sleeve latch members; 96—catch; 98—outer sleeve; 99—ridges;100—engaging posts; 102—first safety cap; 104—radial sockets;106—external threads; 108—internal threads; 110—external threads;112—stop tab; 114—wrenching recesses; 116—lip on first cap; 120—secondcap; 122—outer cap flange; 124—positioning tab; 126—inclined topsurface; 128—bottom surface of tab; 130—inner cap flange; 140—floorfitting; 142—floor fitting tube or spigot; 144—top flange of floorfitting; 146—no-hub connector; 148—ring clamps; 150—cylindrical body;160—adapter; 162—external adapter threads; 164—positioning tabs;166—outwardly extending portion; 168—larger diameter wall; 170—aeratorbox; and 172—flange on bottom of aerator box.

The depicted adjustable extendable sleeve assembly 20 is configured foraxial assembly using snap-fit connections, with optional threadedfasteners being used to further connect and secure the upper base to thelower base and tubular sleeve. As used herein, the relative directionsup and down, upward and downward, above and below are with respect tothe vertical axis when the extendable sleeve assembly in verticallyorientated for installation on a horizontal floor, as generally shown inthe first figure showing the parts in an exploded view along thestraight, longitudinal axis 21. The relative directions inward andoutward are with respect to the longitudinal axis 21 of the extendablesleeve assembly 20 in the vertical orientation as shown in the first,exploded view of the drawings.

Referring to FIGS. 1-21 , the extendable sleeve assembly 20 extendsalong the longitudinal axis 21 and is optionally connected to acorrugated deck (“CD”) plate 22 which is preferably large enough toextend across corrugations of corrugated metal forms used for pouredconcrete structures, such as decks, slabs and floors. The CD plate 22has various openings 24. The CD plate 22 is shown as a rectangular platewith a large circular opening for a pipe and other components describedlater. The CD plate 22 is sturdy enough to support the extendabletubular sleeve on the corrugated form and is typically made of sheetmetal with stamped perforations forming the openings 24. When the CDplate 22 is not used, the lower base 26 is fastened to another support,typically a plywood sheet. During use, concrete is poured onto thesupport to which the extendable sleeve assembly 20 is fastened,entraining the extendable sleeve assembly 20 in the concrete. When theconcrete hardens, a passage through the poured concrete structure isformed by the extendable sleeve assembly 20, allowing elongated membersto pass through the concrete structure, such as plumbing pipes,electrical conduits, electrical wires, fiber optic wires, etc. to passthrough the hardened concrete structure.

The extendable sleeve assembly 20 may include a lower base 26, an upperbase and seal assembly 36, an inner tubular sleeve 60, and either one ofa first or second cap 102, 120, and optionally outer sleeve 98, asdescribed later. The extendable sleeve assembly 20 has the lower base 26that is optionally connected to the CD plate 22 by threaded fasteners,such as screws, that pass-through the openings 24 to fasten the lowerbase 26 and extendable sleeve assembly 20 to the corrugated form. Thelower base 26 has a central opening for a pipe and several openings orlower base sockets 28 for receiving threaded fasteners and severalopenings forming catches 30 (FIG. 8D). The central opening is defined bya short flange encircling the axis 21, with base threads 27 on theflange and encircling the axis 21.

A fire ring 32 configured to hold one or more intumescent members 34 isheld between the lower base 26 and the upper base and seal assembly 36.FIGS. 1, 4 and 11B-11C show two intumescent member 34 a, 34 b shaped asnested, concentric rings having a rectangular cross-section. The firering 32 is preferably of metal or other material that resists hightemperatures. The fire ring 32 is preferably a metal ring with a centralopening and outwardly extending ring tabs 38 that are long enough to beentrained in concrete during use. A plurality of fingers 40 extendupward from the inner edge of the ring that defines the opening in thering. The intumescent members 34 a, 34 b nest inside the fingers 40 withthe fingers 40 preventing lateral movement while the bottom of theintumescent members 34 rest on the annular base of the fire ring 32.

The upper base and seal assembly 36 may be referred to herein as upperbase 36, with both names referring to the same construction. The upperbase and seal assembly 36 has a downward depending flange 42 forming aseal housing sidewall, having a plurality of downwardly extendinglatches 44. The latches 44 are long enough to engage the catches 30 inthe lower base 26 to connect the upper base and seal assembly 36 to thelower base 26 by axial motion (FIG. 1 ). The flange 42 forms a sealhousing sidewall that fits around the outer periphery of the outerintumescent member 34 b with the fire ring 32 sandwiched between theflange 42 of the upper base and seal assembly 36, and the lower base 26.Advantageously, the seal housing sidewall formed by flange 42 ispreferably cylindrical and has a bottom that traps the outwardlyextending ring tabs 38 between the bottom of the flange 42 and the topof the lower base 26. A plurality of upper base sockets 46 arepreferably formed on the outer periphery of the seal housing sidewallformed by flange 42 and have passages aligned with the sockets 28 in thelower base 26 so threaded fasteners can pass through the aligned socketsand secure the upper base and seal assembly 36 to the lower base 26(FIGS. 8B, 8E). The sockets 46, 28 and threaded fasteners are optional.

The upper base and seal assembly 36 has an inwardly extending top plate50 at the upper end of the of the assembly 36, with a depending innerflange 52 forming an opening that is preferably circular. The top plate50 and the inner flange 52 and outer sidewall of the upper base and sealassembly 36 form an inverted, U-shaped cross-section. The top plate 50extends over the top of the intumescent member 34 to restrain upwardmotion of the intumescent members 34 a, 34 b. The inner flange 52 ispreferably a generally cylindrical flange (continuous or intermittent)and aligned with the fingers 40, or extends slightly inward of thosefingers 40 (FIG. 1 ). Thus, a pipe inserted from below the lower basewill be guided by the fingers 40 through the opening formed by the innerflange 52 without the edge of the pipe damaging the inner flange 52. Apipe inserted from above the lower base will be guided by the innerflange 52 so as to avoid an edge of the pipe engaging and damaging anend of the fingers 40.

A flexible diaphragm 54 is over-molded onto the top plate 50. Theflexible diaphragm has an inner opening that is preferably circular andis formed of an elastic material, including neoprene, rubber, or otherstretchable materials. The opening in the diaphragm 54 is preferablysmaller than the intended outer diameter of pipe passing through theextendable sleeve assembly 20 is intended. The extendable sleeveassembly 20 is designed for various pipe diameters so the designed pipediameter is known in advance. The diaphragm 54 preferably has aflexible, annular portion surrounding the opening in the diaphragm 54,with the opening advantageously being formed by a flat-sided, conicalsidewall or formed by a curved sidewall 56 (FIGS. 9A, 9C-D). As bestseen in FIG. 11C, the outer periphery of the top plate 50 may haveconcentric circular indentations or other indentations 58 forming alabyrinth pattern, with the outer periphery of the flexible diaphragm 54being over-molded into those indentations. The indentations 58 andover-molding provide a labyrinth seal to help provide a fluid tightconnection with the upper base 36 on the bottom side of the diaphragm54. A position stop 59 (FIGS. 9A and 12E) extends (preferably axially)along a portion of the seal housing sidewall formed by flange 42 to helpposition an inner tubular sleeve 60 as described later.

In various embodiments, the inner tubular sleeve 60 has a tubular,cylindrical shape, with a base 62 configured to rest on top of the outerportion of the upper base and seal assembly 36 and also extend downwardover the seal housing sidewall formed by the flange 42. To improve thefluid seal between the base 62 of inner tubular sleeve 60 and thediaphragm 54, the bottom of the base 62 may have raised sealingprojections, preferably comprising concentric circular ridges, thatembed themselves in the more flexible material of the over-moldedflexible diaphragm 54, at the outer periphery of the diaphragm 54.

Preferably, as seen in FIG. 12E, a radially outwardly extending sleeveflange 64 on a lower end of the tubular sleeve and base abuts positionstop 59 on the seal housing sidewall formed by the flange 42 of theupper base and seal assembly 36 to position the inner tubular sleeve 60axially relative to the upper base 36 and the lower base 26.

The inner tubular sleeve 60 has first and second sets of spaced-apart,outwardly extending ridges 70, 72 forming intervening slots between therespective ridges of each set. The first ridges 70 and intervening firstslots each extend about half way around a first side or first partialcircumference of the inner tubular sleeve 60. The second set of ridges72 and second slots between those second ridges extend about half wayaround the opposing, second side or second partial circumference of theinner tubular sleeve 60. The ridges 70, 72 on the first and second sidesof the inner tubular sleeve 60 are equally spaced apart about thedistance of a saw blade used by construction workers. The first set ofridges 70 are offset from the second set of ridges 72, with the firstset of ridges preferably being spaced in fractions of an inch and thesecond set of ridges being preferably spaced metrically, preferably inmillimeters. Visible indicia (not shown) on the inner tubular sleeve 60discloses a distance from the bottom of the lower base 26 to each slot,or to the bottom of each ridge (70, 72) forming the slot, so that aworker can cut the inner tubular sleeve 60 to desired, known length bycutting at a slot, with the saw blade guided by the opposing ridges 70,72 on each side of the slot. The ridges may be viewed as graduations onthe outside of the inner tubular sleeve 60. The ridges 70, 72 andprinted indicia identify a plurality of graduated distances from thebottom of the lower base 26. These ridges and grooves are known anddescribed in more detail in U.S. Pat. No. 9,086,174 and U.S. PublishedApplication No. 2015/0121783, the complete contents of which are herebyincorporated by reference.

The first and second sets of ridges 70, 72 and their intervening slotsare in radially aligned planes extending orthogonal to axis 21. Thesesets of ridges 70, 72 are separated by first and second longitudinalchannels 74 a, 74 b located on opposing sides of the inner tubularsleeve 60. As desired, the printed indicia may be located in one or bothlongitudinal channels 74 a, 74 b, or on the outer sides of inner tubularsleeve 60 in the spaces between adjacent ridges 70, 72. The ends of twoadjacent ridges 70 or two adjacent ridges 72 within each set of ridgesmay be joined by axially extending end segments 76 (FIGS. 10C, 18 ),with alternating pairs of ridges joined by offset end segments 76 thatare offset circumferentially a short distance from end segments 76 eachother to form staggered axial end connections. A latching protrusion 78(FIGS. 14A, 17-18 ) may extend axially from or near the axiallyextending end segments 76 to form a snap lock connection describedlater. The ridges 70, 72 are parallel to each other with the ridges 70being offset axially relative to the ridges 72. By cutting the innertubular sleeve 60 off at a particular ridge 70, 72, or the slotassociated with that particular ridge, a user can determine the maximumheight of the extendable sleeve assembly 20 and thus adjust the lengthof the extendable sleeve assembly 20.

Referring to FIGS. 10A-10B, 14A, 15A and 18 , the inner tubular sleeve60 optionally has one or more whisker supports 80 extending outwardsfrom the inner tubular sleeve 60, preferably at the bottom of the innertubular sleeve 60 and more preferably from the outer portion of theinner tubular sleeve 60 by the base 62. A whisker assembly 81 having aplurality of flexible, elongated whiskers 82 (FIGS. 20A-20B) mounted toa whisker base 84 having a male (protruding) whisker connector 86 on abottom of the base 62, releasably fasten or connect to one of thewhisker supports 80. The whisker supports 80 have a female (recessed)whisker connector 88. The whisker connectors 86, 88 releasably engage tohold the whisker assembly 81 to the whisker support 80. The male andfemale connectors 86, 88 may be on opposing parts (support 80 or whiskerassembly 81) and of varying configurations to releasably engage. Theconnectors 86, 88 allow a user to manually attach a whisker assembly tothe whisker support or manually remove the whisker assembly from thesupport. The whisker base 84 may optionally have one or more axial,through-holes so threaded fasteners may be used to optionally secure thewhisker assembly to the safety cap 102 as described later.

Referring to FIGS. 10A-10B, 14A, 15A and 18 , the inner tubular sleeve60 advantageously has at least one, and preferably has a plurality ofinner sleeve sockets 92 connected to the bottom of the inner tubularsleeve 60, preferably connected adjacent the base 62 and extendingoutward of the sleeve flange 64. The inner sleeve sockets 92 preferablyalign with the lower base sockets 28 and the upper base sockets 46 sothreaded fasteners can pass through the aligned sockets and secure theinner tubular sleeve 60, upper base 36 and the lower base 26 together(FIGS. 8B, 8E). The threaded fasteners through the aligned sockets alsourges the sealing projections against the outer periphery of theflexible diaphragm 54 to form and maintain a fluid tight seal betweenthose parts. The sockets 28, 46 and 92 and threaded fasteners areoptional, but preferable. The threaded fasteners passing through eachset of aligned sockets 28, 49 and 92 advantageously extend along afastener axis, with a different fastener axis extending along each setof aligned sockets and each fastener axis advantageously but optionallyspaced symmetrically about the longitudinal axis or spaced equallyaround a common circumference centered on longitudinal axis 21.symmetrically Advantageously, one of the sockets 92 is immediatelyadjacent whisker support 80, at least one of which is vertically alignedwith the channels 74 a-b or end segments 76.

Extending outward from the bottom portion of the inner tubular sleeve 60are a plurality of sockets 92. The sockets 92 preferably have a passedtherethrough sized to accept a threaded fastener. The sockets 92preferably extend radially outward and at locations selected to alignwith sockets 28 in the lower base 26 and sockets 46 in the upper baseand seal assembly 36. Threaded fasteners may pass through the alignedpassages in the sockets 92, 46 and 28 to fasten together the innertubular sleeve 60, upper and lower bases 36 and 26. The threadedfasteners (FIGS. 8B, 8E) provided an increased stability and strengththat helps maintain the integrity of the connected parts in the roughconstruction environment.

Depending downward from the bottom portion of the inner tubular sleeve60, and preferably extending downward from the sleeve flange 64, are atleast one and preferably a plurality of sleeve latch members 94. Thesleeve latch members are located to axially engage recesses or catches96 (FIGS. 12B-12C) formed in the upper base and seal assembly 36 to holdthose parts together. In the depicted embodiments, the sleeve latchmembers 94 are male latch members with an outwardly facing barb andengage female catches 96 or female latch members having a ridge, lip orinwardly facing barb to engage the male latch member (FIGS. 12B-12C).The sleeve latch members 94 and catches 96 allow axial movement of theinner tubular sleeve 60 and upper base and seal assembly 36 to fastenthe parts together using a snap-fit connection. The latches arepreferably sufficient to hold the parts together for the intended usewithout the threaded fasteners passing through the sockets as describedabove.

Referring to FIGS. 11B and 13 , an outer tubular sleeve 98 is optionallyprovided. The outer sleeve 98 is a tubular sleeve with ridges 99extending outward from the exterior of the sleeve. If multipleextensions are to be used, the ridges 99 may comprise the sets of ridges70, 72 described on the inner tubular sleeve 60, or an extension may bethreaded into the top end of the outer sleeve 98 using internal threads108 described later. The ridges 99 are preferably circumferentialridges, equally spaced. The ridges 99 stiffen the sleeve and engage thepoured concrete during use. The outer sleeve 98 is larger in diameterthan the inner tubular sleeve 60 and fits over the inner tubular sleeve60 to form nested, coaxial sleeves. For example, the inner tubularsleeve 60 may have a 5-inch inner diameter and the outer sleeve 98 mayhave a 5.5-inch diameter. Advantageously, the whisker support 80 extendsfar enough away from the generally cylindrical wall of the inner tubularsleeve 60 that the outer sleeve fits between the cylindrical wall of theinner tubular sleeve 60 and the outer whisker assembly 81 when connectedto the whisker support.

The outer tubular sleeve 98 has a plurality if engaging posts 100extending radially inward. The engaging posts 100 are preferably alignedin vertical columns and spaced vertically apart a distance correspondingto the location of the end segments 76 and adjacent grooves 70, 72forming those end segments, both on the inner tubular sleeve 60, so theengaging posts can fit between the ends of adjacent grooves 70 or 72.The engaging posts 100 are vertically aligned in groups and each groupof engaging posts 100 is spaced circumferentially apart a distancecorresponding to the circumferential location of the channels 74 a, 74b. The number of groups of engaging posts 100 preferably corresponds tothe number of channels 74 a, 74 b, but may be as small as one group ofvertically aligned engaging posts. In use, each group of engaging postsmay be aligned with and moved vertically along a different one of thechannels 74 a, 74 b until a desired height of the outer sleeve 98 andsafety cap 102 is reached, at which point the outer sleeve and the innertubular sleeve 60 are rotated relative to each other so the engagingposts 100 fit between the adjacent ends 76 of a set of ridges 70 or 72.The ridges 70, 72 are slightly offset adjacent the end segments 76 andthe latching protrusion 78 may engage and hold the engaging post inposition. The offset allows the adjacent ridges 70 or 72 to guide a sawblade in the groove between the adjacent ridges, while the offset avoidsthe cut and allows enough structure to engage the engaging ends 100 andmaintain the position.

A plurality of radially oriented sockets 104 are formed in the wall ofthe outer tubular sleeve and preferably have a radial passage extendingthrough the socket. In use, a threaded fastener may be screwed througheach radial socket 102 to secure the outer tubular sleeve 98 to theinner tubular sleeve 60. The threaded fasteners extending through theradial sockets 104 provide a stronger connection than the engagement ofthe engaging posts 100 and ends of the adjacent ridges 70, 72. Duringuse in construction, the extended sleeve assembly 20 may be hit byworkers or equipment from various directions and the threaded connectionachieved by the radial sockets 104 helps maintain the height of theextendable sleeve assembly 20 once it is set.

The outer tubular sleeve 98 has external threads 106 on its lower endwhich can threadingly engage base threads 27 during use, and in that usethe end of the outer sleeve 98 with threads 106 will be at the top ofthe outer sleeve 98 with the outer sleeve below the lower base 26. Theouter sleeve 98 has internal threads 108 on its upper end, preferablyformed on the inside of a slightly offset flange of slightly largerdiameter than the outer sleeve 98. The slightly offset flange preferablyforms a shoulder 109 (FIG. 13A, 13D).

Referring to FIGS. 1-3, 11B, and 13A-13C, a first cap, a safety cap 102,has external threads 110 on its outward facing edge and a plurality ofdepending, stop tabs 112. The external threads 110 are configured tothreadingly engage internal threads 108 on outer tubular sleeve 98. Thesafety cap 102 is advantageously configured so its top surface is flushwith the top of the outer sleeve 98 during use. The tabs 112 are sizedso that when the top surface of the safety cap 102 is flush with the topedge of the outer sleeve 98, the ends of tabs 112 abut the flange 109.Thus, the flange 109 acts as a position stop for the tabs 112 and safetycap 102. There are preferably at least two stop tabs 112, andadvantageously from two to eight stop tabs 112, each stop tab extendingan axial distance of about 0.25 to 1 inch. The external threads 110 arefew in number and preferably comprise multiple lead threads, such asdouble lead threads that extend about three times around thecircumference of the cap. The safety cap 102 has a plurality ofwrenching recesses 114 so a wrenching tool (not shown) can engage therecesses and remove the cap after the extendable sleeve is encased inconcrete. The safety cap 102 has a female whisker connector 88 in itstop surface, preferably in a centrally located recess, so that whiskerassembly 81 may be connected to the top of the safety cap 102.

In some cases, the concrete is very thin and a very low height isrequired for the inner extension tube 60. In order to accommodate thinconcrete structures, such as 2.5-3.5 inches thick, the first cap 102 hasexternal threads 110 that are few in number, preferably about 3-4complete threads. The stop tabs 112 may be broken off so that the heightor thickness of the first cap along axis 21 is the same as that of theflange containing the 3-4 threads. Referring to FIG. 13D, the first caphas an inwardly extending lip 116 having an inclined lower surface and aflat top surface to form a catch. The lip 116 can be continuous orintermittent. The inner tubular sleeve 60 is cut to the desire lengthand the first cap 102 pushed over the open end of the sleeve, with thelip 116 located to engage one of the ridges 70, 72 extending outwardsfrom the inner tubular sleeve 60. The lip 116 is located a distance fromthe inside surface of the top of the first cap 102 so that the lip 116can engage one of the ridges 70, 72. This leaves the external threads110 exposed to the concrete and those threads are entrained in thepoured concrete. After the concrete hardens, a pipe may be pushed fromthe bottom of the extendable sleeve assembly 20 upward against theinside surface of the first cap 102 with enough force to eitherdisengage the lip 116 from the engaged ridge 70, 72, or to shear the lipoff, or to deform the lip enough that the cap can be removed from thehardened concrete.

As best seen in FIG. 13D, the lip 116 on the inside of the dependingflange of the cap 102 extends inward and is located opposite theexternal threads 110. The lip 116 has an inclined bottom end facingdownward and toward the longitudinal axis 21 so a ridge 70, 72 of atubular sleeve can more easily slide past the lip to engage the catchformed by an orthogonal surface on the lip. The flat surface forming thecatch is located an axial distance from the bottom, inside surface ofthe cap sufficient to engage and catch one of the ridges 70, 72. Thus,if the ridges 70, 72 are located a distance d from the adjacent distalend of the tubular sleeve from which the ridges extend, the flat surfaceof the lip 116 forming the catch is located a distance slightly greaterthan the distance d (to account for the thickness of the ridge 70, 72)to engage the closest of the ridges during use when the cap 102 isplaced onto the tubular sleeve having such ridges.

In use, the intumescent material 34 is placed on the fire ring 32,guided by the fingers 40. The fire ring 32 and intumescent material 34is placed on the lower base 26 and then the upper base and seal assembly36 is placed over the intumescent material 34 and the latches 44 on theupper base and seal assembly 36 engage the catches 30 in the lower base26 to fasten the upper base and seal assembly 26 and lower base 26together, trapping the fire ring 32 and intumescent material between theupper base and seal assembly 36 and the lower base 26. The latches 44engage the catches 30 through relative axial movement of the upper baseand seal assembly 36 and the lower base 26. The inner tubular sleeve 60is placed over the upper base and seal assembly 36 and the sleeve latchmembers 94 on the inner tubular sleeve 60 engage catches 96 on the upperbase and seal assembly 36 as seen in FIG. 12C, to connect the innertubular sleeve 60 to the upper base—through relative axial movement ofthe parts. The sleeve latch members 94 and catches 96 hold the sealingprojections against the outer periphery of the diaphragm 54 to provide afluid tight seal. Optional but preferably threaded fasteners passthrough sockets 28, 46, 92 (FIGS. 8B, 8E) to secure the upper and lowerbases 36, 26 together and to hold the intumescent material and the firering 32 in position with the ring tabs 38 extending outward a distancesufficient to be entrained in concrete during use. By entraining thering tabs 38 in concrete, the intumescent material 34 is maintained inposition even if the plastic used in the extendable sleeve assembly 20(especially bases 26, 36) and plumbing pipes melts or is burnt away. Thefasteners passing through sockets 92 also more securely hold the innertubular sleeve 60 to the upper and lower bases 36, 26.

The outer sleeve 98 is connected to the inner tubular sleeve 60 byaligning engaging posts 100 with channels 74 a, 74 b and moving thesleeves 60, 98 relative to each other until a desired height of theextendable sleeve assembly 20 is achieved, at which point the outersleeve 98 and inner tubular sleeve 60 are rotated to engage the posts100 with the selected adjacent grooves 70, 72 separated by end segments76. Engaging protrusions 78 engage and hold the engaging posts 100 inposition. Threaded fasteners through radial sockets 104 securely connectthe inner and outer tubular sleeves 60, 98, respectively. The safety cap102 is screwed onto the end of the outer sleeve 98. The distance fromthe bottom of the lower base 26 to the top of the outer sleeve 98 andsafety cap 102 is thus predetermined. The whisker assembly 82 is removedfrom the support 80 and optionally connected to the connector 88 in theoutside of the safety cap 102. The lower base 26 is fastened to aconcrete support—typically by nails or screws passing through the base.As desired, the lower base 26 may be connected to CD plate 22 which inturn is fastened to a support such as a corrugated support by threadedfasteners. The lower base 26 is connected to the CD plate 22 or othersupport by threaded fasteners, or snap-lock mechanisms. The extendablesleeve assembly 20 is then entrained in concrete, with the whiskerassembly extending above the finished concrete surface to identify thelocation of the cap 102 and the extendable sleeve assembly 20 after theconcrete surface is finished and hardened. The safety cap 102 is removedfor use of the entrained extendable sleeve assembly 20. A pipe isinserted through the opening in the flexible diaphragm 54 either fromthe top of the assembly, or from the bottom of the assembly, with thediaphragm resiliently urged against the outer surface of the pipe by thedifference in sizes between the pipe and the opening in the diaphragm.

The above description provides an extended length of the extendablesleeve assembly 20 for thick concrete structures. For concretestructures with a smaller thickness a different cap may be used.Concrete structures with a thickness of 7.5 inches, 7.75 inches and 8inches are common. It is cumbersome and labor intensive for a user tomanually cut the inner tubular sleeve 60 to the specific length neededfor a particular concrete structure at a jobsite, and to do soaccurately. If the tubular sleeve is cut too short, the entire sleevecannot be used for that floor thickness and must be discarded tolaboriously saved and inventoried for potential use with a differentfloor thickness. Sometimes the cap on the end of existing sleeves mayhave a threaded connection which allows the top surface of the cap to beextended above the top edge of the sleeve—but that provides acontinuously variable height adjustment which is difficult to measureand which may be inadvertently changed if workers contact and rotate thecap (thereby changing its height). The second cap 120 provides anincremental adjustment for the height.

Referring to FIGS. 14A-14D, a second, incrementally positionable cap 120is provided having a flat top, a wrenching recesses 114 and a femalewhisker connector 88—just as first cap 102. But the second cap 120 has adepending outer cap flange 122 at its outer periphery with at least one,and preferably a plurality of pairs of positioning tabs 124. Thepositioning tabs 124 may extend radially inward toward axis 21 and arelocated a predetermined distance below the top surface of the second cap120. The positioning tabs 124 preferably have a top surface 126 that isinwardly and downwardly inclined and a flat bottom surface 128. Theinclined top surface 126 is inclined at an acute angle relative to thebottom surface 128 so the inclined surface 126 faces an underside of thesecond cap 120. The positioning tabs 126 are sized to fit between theridges 70, 72 and into the slots between those ridges.

During use, the tab 124 fits between two adjacent ridges in one of thesets of ridges 70 or 72. The flat bottom 128 rests on the lower of twoadjacent ridges in the group of ridges 70 or 72 so that a downward forceon the cap 120 presses the tab 126 against the lower of the two adjacentridges to maintain the position of the cap 120 and the inner tubularsleeve 60 to which the cap 120 is connected. The tabs 124 are located tobe spaced circumferentially around the outer cap flange 122 a distancecorresponding to the circumferential spacing of the vertical channels 74a, 74 b. The inner tubular sleeve 60 is cut to the rough heightneeded—but at a location so that the total height of the lower base 26,the upper base 36 and the inner tubular sleeve 60 is less than thethickness of the concrete structure. The second cap 120 is rotated sothe tabs 126 are aligned with different ones of the vertical channels 74a, 74 b and the cap 120 is then positioned axially relative to the innertubular sleeve 60 so the tabs align with a pair of adjacent ridges inthe sets of ridges 70, 72, and the cap 120 is then rotated so the tabs126 slide into the space or groove between the desired ridges 70, 72.Because the top of the second cap 120 is a known distance from the tabs126 and the bottom surface 128 of the tabs 124, the location of the topsurface of the cap 120 is also known. The ridges 70, 72 are preferablyspaced in increments that allow the position of cap 120 to be manuallyadjusted to vary the total height of the extendable sleeve assembly 20to be 7.5, or 7.75 or 8 inches for examples, preferably by engaging thetabs 124 with three different, vertically adjacent ridges 70, 72 in thesets of ridges 70, 72.

The tabs 124 are preferably at the bottom of the outer cap flange 122and the length of the outer cap flange 122 determines how many groovesbetween the ridges 70, 72 may be engaged. The outer cap flange 122 ispreferably about 0.5 to 1-inch long. A longer length of outer cap flange122 limits the minimum height of the extendable sleeve assembly 20. Theshorter length flange (0.5 to 1 inch) allows adjustment for the mostcommon thicknesses of the concrete structure. Advantageously, the outercap flange 122 is from 0.1 to 0.5 times the length of the inner tubularsleeve 60. Optionally, radial flange sockets can be formed in the outercap flange 122 so threaded fasteners can be screwed through the outercap flange 122 and into the inner tubular sleeve 60.

The inclined top surface 126 of the positioning tabs 124 are inwardlyand downwardly inclined so that they more easily slide off the upperridge 70, 72 adjacent the tabs 124. After the concrete is poured andhardened, the outer cap flange 122 is embedded in the concrete. A pipemay be inserted from below, through the diaphragm 54 and against theinside of the second cap 120 to force the cap 120 out of the concrete.As seen in FIGS. 14A and 14D, the cap 120 preferably has an inner capflange 130 radially inward from the outer cap flange 122 and parallelthereto and concentric therewith. The inner cap flange 130 is located tofit inside the inner surface of the inner tubular sleeve 60, preferablyvery close to that surface without binding. The inner flange 122 extendsdownward a distance that is about where the positioning tab 126 begins.As a pipe is pushed upward through the extendable sleeve assembly 20 andagainst the bottom of the second cap 120, the positioning tabs 124 willeither shear off because of the concrete that fills the grooves betweenthe ridges 70, the base threads 27, or the positioning tabs 124 willdeform and urge the top portion of the inner tubular sleeve 60 inward.The inner flange 130 forms a ring that helps strengthen the top portionof the inner tubular sleeve 60 and helps prevent the tabs 124 frompushing the top portion of the inner tubular sleeve 60 inward andcracking the concrete or breaking the top portion of the inner tubularsleeve 60. The inner flange 130 is optional.

The cap 120 thus has a circular outer periphery with a generally flattop surface and the flange 120 depending from the outer periphery of thecap 120 and encircling the periphery of the cap 120. The cap 120 isremoved after the concrete structure is poured and advantageously, thetop surface of the cap 120 is at or very near the surface of theconcrete structure so that little or no concrete overlays the cap 120. A“generally flat” top surface helps reduce the entrainment of the cap 120and avoids outwardly extending protrusions that can engage the rotatingblades of finishing trowels or other concrete finishing equipment, butallows recesses. The positioning tab 124 has a bottom surface 128 thatis orthogonal to the longitudinal axis 21 during use. The positioningtab 124 has a width that is smaller than the circumferential space Wbetween the end segments 76 which forms a channel 74 a or 74 b on theouter surface of the sleeve, which channel 74 a or 74 b is generallyparallel to the longitudinal axis 21. The axial length of thepositioning tab 124 is smaller than the axial distance between theoutwardly extending ridges 70, 72 between which the positioning tab 124fits during use. Advantageously there may be between two and sixpositioning tabs 124, spaced so each tab fits along a different one ofthe channels 74 a, 74 b between the end segments 76. The inner,depending cylindrical flange 130 has an outer diameter slightly smallerthan the inner diameter of the inner tubular sleeve 60 to which the cap120 fastens.

Referring to FIGS. 17-19 , the extendable sleeve assembly 20 may be usedwith a no-hub connector 146 and a plumbing floor drain fitting 140(e.g., drain fitting, toilet drain fitting) with a top flange 144 and alower drain tube or spigot 142 to provide a sufficiently rigid assemblyto be used in construction and while concrete is poured to entrain theparts. Currently, the extendable sleeve assembly 20 is fastened to aconcrete form by screwing or nailing the lower base 26 to the concreteform, or fastening the lower base 26 to a CD plate 22 which is in turnnailed or screwed or otherwise fastened to a concrete form. After theextendable sleeve assembly 20 is fastened to a concrete form andadjusted to its desired height, a floor drain fitting 140 is positionedon top of the extendable sleeve assembly 20 and held in position bymetal rods and wires positioned in whatever way the user decides is mostexpedient to support the floor drain in position until the concrete ispoured and hardened. Because these floor drain fittings 140 are heavy,typically of cast iron, the required support for these fittings issturdy so as to position and support the floor drain fitting independentof the extendable sleeve assembly 20. Typically, the floor drain fitting140 has a lower tube 142 that fits inside the inner tubular sleeve 60 orouter tubular sleeve 98. Occasionally, the lower tube 142 abuts the endof those sleeves 60, 98 but that is undesirable because a good fluidconnection is not ensured and pushing downward on the inner tubularsleeve 60 may cause it to tile and misalign, allowing concrete to enterthe passage formed by the extendable sleeve assembly 20. The floorfittings 140 are typically symmetric about the longitudinal axis 21.

The assemblies of FIGS. 1-16 and especially 17-19 may use a no-hubconnector 146 to securely fasten the floor fitting 140 to the top of theextendable sleeve assembly 20 such that the extendable sleeve assembly20 self supports the drain fitting during pouring of the concrete andfinishing with no support struts, wires or braces extending between thesupport on which the concrete is poured and any part of the base,sleeve, no-hub connector or floor fitting to stabilize the parts asconcrete is poured, finished and sets. The no-hub connector 146 may havea cylindrical body with opposing ends and a radially compressingmechanism at each opposing end to move the ends radially inward to sealagainst another part. The depicted no-hub connector 146 is a tubularbody 150 with inwardly deformable ends. A ring clamp 148 encircles eachend of the tubular body 150. More than one ring clamp may be used oneach end of the tubular body. A thick, rubber hose is typically used toform the body 150, with a thick, stiff hose, and/or a metal sheatharound the tube and between the ring clamps to stiffen the body 150 atthe central part of the body. The metal sheath typically comprises acylindrical shape with a lengthwise slot to allow the diameter to changeas the connector is tightened, and with outwardly curved or rolled endsto avoid cutting into connected parts. A first end of the connector 146fits over the outer end of the inner tubular sleeve 60 (or outer tubularsleeve 98) and a second end of the connector 146 fits over the tube 142of the floor drain fitting 140. The ring clamps 148 are tightened tosqueeze the body 150 against the sleeve 60 (or 98) and tube 142 to forma tight connection. A slotted metal sheath may encircle the tubular bodyand the slot allows the sheath to contract as the ring clamps aretightened, with the metal sheath providing axial support to stabilizethe floor fitting.

In the described embodiments for use with the extendable sleeve assembly20, the no-hub connector 146 allows a small lateral offset of the joinedtubes, allows a small axial offset of the joined tubes, and allows tubesof different diameter to be joined if the difference in diameters issmall enough, all while maintaining a desired alignment of the parts.The body 150 is advantageously of rubber, EDPM, polyisoprene, includingsilicon rubber, or other suitably stiff but resiliently deformablematerials that are stiff enough and optionally have a high enoughsliding friction coefficient to maintain the position and orientation ofthe clamped tubular parts without noticeable creep when creep ismeasured over a few days. Thus, the position and orientation of a floorfitting 140 having a lateral dimension of about 12 inches, is believedto be maintained within about 0.1 inch of the initial position whenconcrete is poured and within about 0.15 inches after finishing, alongthe X axis, along the Y axis, and along the Z axis.

The length of the no-hub connector 146 and the stiffness of theconnector are selected to provide a sufficiently strong and stiffsupport that the weight of the floor drain fitting 140 may be supportedin its use position by the no-hub connector—without the need for furthersupport as in the prior art, from, for example, support wires or strutson the floor drain fitting 140. Thus, the floor drain fitting 140 issupported on the support sheet or corrugated deck onto which theconcrete structure is poured, only by the base (26, 36 and 22 if a CD isused), the inner tubular sleeve 60 and the no-hub coupler 146. Thenormal connection of the base 26, 36 or other base to the support(typically plywood or CD) onto which the concrete is poured is believedsufficient, such as nails or threaded fasteners or bolts on CD. Asdesired, additional fasteners may be used to connect the base 26 or CDplate 22 to the support onto which concrete is poured to form theconcrete structure. But no external braces, wires or support strutsextending between the support on which the concrete is poured, and theparts of the tubular passage formed by the base, sleeve(s), no-hubconnector and floor fitting.

The top flange 144 typically has plumbing connections on it and must beparallel to the concrete surface, and the no-hub connector 146, theinner tubular sleeve 60, the lower base 26, and the upper base and sealassembly 36, must maintain the desired position and orientation of thefloor drain fitting 140. The floor drain fitting 140 is typically madeof cast iron and very heavy and the no-hub connector 146 must maintainthe desired position and orientation of the floor drain fitting 140.Advantageously,

Advantageously, the diameter of the inner tubular sleeve 60 is selectedto be about the same diameter of the no-hub connector 146 so that a body150 of uniform diameter may be used for the no-hub connector 146. Inthis context, “about the same diameter” means within 10% of the largestouter diameter. Thus, if the largest outer diameter of two tubes is 2inches, about the same diameter allows a plus or minus 0.2 inchvariation between the two tubes. If the differences between the floordrain fitting outlet tube 142 and the tubular sleeves 60, 93 are greatenough then a connector 146 may be selected which has a body 150 thatchanges diameter from one end to the other, although advantageously achange in diameter of more than one inch is not desirable. The threadedfasteners extending through the lower base sockets 28, the upper basesockets 46, and the sockets 92 on the inner tubular sleeve 60, connectthe sleeve and base together to form a strong and stiff structure thatis believed to help maintain the position and orientation of the floorfitting 140 and its top flange 144. Securing the threaded fastenerspassing through these sockets 28, 46 and 92 to the support onto whichthe concrete is poured to form the concrete structure, anchors theseconnected base and sleeve parts to provide a sturdy support for theno-hub connector 146 and the floor fitting 140.

The assembly and use sequence is modified slightly when the floorfitting 140 is supported by the extendable sleeve assembly 20 as no cap102 or 120 is required because the floor fitting 140 is connected by theno-hub connector 146 to the top end of the inner tubular sleeve 60 or toany extended sleeve as by outer sleeve 98. But the floor fitting 140itself is covered to prevent concrete from entering it so a cap or coverof sorts is provided and that floor fitting cover may have be configuredto have the whisker assembly 81 removably connected to the fitting coverso the cover may be more easily located after finishing of the concrete.The floor fitting cover is advantageously flat (excluding the whiskerassembly connected to the cover) so it does not engage the concretefinishing tools and mar the concrete surface or be damaged by thosefinishing tools.

If only the inner tubular sleeve 60 is used, then the floor fitting 140has its tube or spigot 142 fit inside the top end of the no-hubconnector 146 while the top end of the inner tubular sleeve 60 fitsinside the bottom end of the no-hub connector 146. The ring clamps 148are then tightened while the floor fitting 140 is held in its desiredposition and orientation. Advantageously the top flange 144 is parallelwith the anticipated exterior surface of the concrete structure, and thefloor fitting tube or spigot 142 and the no-hub connector 146 are bothaligned with the longitudinal axis 21, as is the inner tubular sleeve60, the lower bases 26 and the sockets 46. The base 26 is fastened tothe support and concrete is poured onto the support, advantageously withthe floor fitting 140 covered so concrete does not enter it duringpouring the concrete structure or finishing the exterior surface of theconcrete structure.

This assembly of the floor fitting 140, the no-hub connector 146, theinner tubular sleeve 60, along with the upper base and seal assembly 36and the lower base 26 is advantageously arranged and aligned along acommon longitudinal axis 21 while the lower base 26 is fastened to thesupport onto which the concrete is poured to form the concretestructure. That support is typically a series of plywood sheets, a metalCD, or other support. Alternatively, the assembly of the floor fitting140, the no-hub connector 146, the inner tubular sleeve 60 and the upperbase and seal assembly 36 and the lower base 26 may be created andconnected separately, and then fastened to the support onto which theconcrete structure is poured, be it, by fastening the lower base 26 tothe support.

The lower base 26, the upper base and seal assembly 36 and inner tubularsleeve are connected axially by latch and catch, snap-fit connections.Preferably, the lower base 26 also connects to the CD plate 22 by latchand catch, snap-fit connections. The threaded fasteners may be used toprovide a more secure connection, but may be omitted. Advantageouslythough, the inner tubular sleeve 60, the upper base and seal assembly 36and the lower base 26 are connected not just by snap-fit connections,but are further connected by threaded fasteners through the sockets 92,46 and 28 in those respective parts. A threaded fastener such as a boltwith one end above socket 92 and the other end below base 26 and socket28 may be used to interconnect these parts and hold them securelytogether, and the connected parts may then be fastened to the supportfor the concrete structure by fasteners passing through the lower base26. Alternatively, one head of the bolt may be on the bottom side of thesupport for the poured concrete structure, be that a sheet of plywood ora corrugated deck (“CD”) to fasten the base and sleeve more directly tothe support for the poured concrete. To fasten the extendable sleeveassembly 20 to the support for the concrete structure does not require abolt, as a threaded fastener such as a screw may pass through thesockets 92, 46 and 28 and also through the support for the pouredconcrete structure, be that a sheet of plywood or a corrugated deck(“CD”) so as to more directly fasten the inner tubular sleeve 60, andthe upper base and seal assembly 36 and the lower base 26 together andto the support for the concrete surface. These above connections may beused regardless of whether a floor fitting 140 is used.

If the poured concrete structure is thicker than provided by the upperbase and seal assembly 36 and the lower base 26, the inner tubularsleeve 60, the no-hub connector 146 and the floor fitting 140, thelength may be increased by either or both of using a longer no-hubconnector 146 or adding a second sleeve. Advantageously, the no-hubconnector 146 is relatively short, typically four 4 to 8 inches long andadvantageously about 4 to 6 inches long. The longer connectors 146 usemultiple ring clamps 148 on each end of the connector. A stiffeningsheath of metal or plastic may be used between the ring clamps 148 andbody 150 to stiffen the no-hub connector 146 and stabilize the floorfitting 140. If the body 150 is thicker and the stiffening sheath strongenough, a few inches of length may be obtained by using a stiffeningsheath on the no-hub connector 146. Even if added length is not needed,the stiffening sheath may be used to further strengthen and stiffen theno-hub connector 146.

Alternatively, a thicker concrete structure with the extendable tubularassembly 20 supporting the floor fitting 140 may be achieved by using anextended sleeve, such as the second sleeve 98. The connection betweeninner tubular sleeve 60 and the outer sleeve 98 must be sufficientlystrong and stiff to support the added weight of the floor fitting 140without additional stabilizing and support devices such as wires, rods,etc. A sufficiently strong and stable connection is believed to beformed providing mating threads on mating ends of the inner and outersleeves for an incremental extension of length, or by fitting the outersleeve over the inner tubular sleeve 60 and using the engaging posts 100mating with ridges 170, 172 to adjust the length, and then usingthreaded fasteners passing through radial sockets 104 to interconnectthe overlapping portions of the inner and outer sleeves.

The diameter of the end of the inner tubular sleeve 60 and the outersleeve 98 and the diameter of the floor fitting tube or spigot 142 areadvantageously about the same. Any slight differences in diameter may beaccommodated by combining inner tubular sleeve 60 and the outer sleeve98, recognizing that outer sleeve 98 is slightly larger in diameter thaninner tubular sleeve 60, and using threaded fasteners to connect the twosleeves 60, 98 allows not only an adjustable length but a strong andstable interconnection between the sleeves. Further adjustment indiameter may be achieved by using the adaptor 160, described above,which may have a selected outer diameter. Radial sockets 104 may beprovided to the adaptor 160, to the top portion of inner tubular sleeve60, or to both to accommodate threaded fasteners passing through theadaptor 160 and into the inner tubular sleeve 60 to interconnect,strengthen and stabilize the connection. The no-hub connector 146 mayalso accommodate some change in diameter, and if a no-hub connector 146is used with a non-uniform diameter along the length of its body 150,then advantageously the bottom end of the no-hub connector 146 is oflarger diameter than the top end of the no-hub connector 146, with thering clamps 148 being of appropriate diameter for use with therespective connector ends of different diameter.

After the extendable sleeve assembly 20 is connected to the no-hubconnector 146 and floor fitting 140, and the base 26 or CD plate 22 isconnected to the support onto which the concrete is poured, the heightand orientation of the floor fitting and any flange 144 is set, bymoving the extendable sleeve assembly 20, the no-hub connector 146 andfloor fitting. In various embodiments the extendable sleeve assembly 20is believed to be sufficiently stiff and stable when fastened to thesupport onto which concrete is poured that it does not shift laterallyor angularly, and it allows a stable height adjustment and position tobe set. The no-hub connector 146 allows some small adjustment in heightand allows adjustment in orientation of the floor fitting flange 144,with tightening of the ring clamps 148 fixing the orientation andheight. The resulting assembly, when tightened and positioned, isbelieved sufficiently stable to allow concrete to be poured and entrainthe assembled and oriented parts and to maintain the alignment andorientation of the parts as the concrete cures and is finished—withoutthe need for additional wires or inclined support struts to brace theheavy floor fitting in position. The base, the sleeve and the no-hubconnector 146 are thus self-supporting of the floor fitting so the floorfitting top flange is substantially perpendicular to the longitudinalaxis. The impact forces of workers hitting the extendable sleeveassembly 20 supporting the floor fitting 140 may shift the position ororientation of the floor fitting, thus, the orientation and position areadvantageously checked shortly before pouring concrete to entrain theextendable sleeve assembly 20 and the floor fitting 140. The thatposition and orientation are believed to be maintained during pouringand curing of the concrete, and absent unusual circumstances, duringfinishing of the concrete surface.

The floor fitting flange 144 is typically substantially perpendicular tothe longitudinal axis. The floor fitting flange 144 may be slightlyinclined as the exterior surface of the concrete structure may beslightly inclined by about 1-3° for drainage, and “substantiallyperpendicular” is used to encompass this variation for drainage. If thefloor fitting 140 is intentionally orientated with the flange 144 at agreater inclination, the extendable sleeve assembly 20 and no-hubconnector 146 described herein are believed sufficient to maintain thatorientation. The extendable sleeve assembly 20 and no-hub connector 140are not intended for supporting the floor fitting 146 at any appreciabledistance offset laterally from the longitudinal axis 21 or forsupporting a floor fitting 140 that is sufficiently asymmetric that ithas its center of gravity offset substantially from the longitudinalaxis 21. In certain embodiments, the extendable sleeve assembly 20 andno-hub connector 140 may be configured to support a floor fitting 140 of50 pounds with a center of gravity offset laterally a distance of about0.5 inches from the longitudinal axis 21. But preferably the weight andcenter of gravity offset from the longitudinal axis 21 are about 25pounds or less, offset laterally about 0.5 inches or less. When thecenter of gravity of the floor fitting is within the above offsetdistances, the floor fitting is substantially centered on thelongitudinal axis 21. There is thus provided a method and apparatus forself-supporting a floor fitting by the extendable sleeve assembly 20using a no-hub connector, during pouring of the concrete, andadvantageously during finishing of the concrete surface.

Referring to FIGS. 15-16 , an adapter 160 is shown for changing thediameter of the extendable sleeve assembly 20. The adapter has a firstend with external adapter threads 162 and inwardly extending positioningtabs 164. An outwardly extending portion 166 shown as a radial extendingshoulder which then extends upward to form larger diameter sidewall 168of the adapter. The positioning tabs 164 are located circumferentiallyto fit into vertical channels 74 a, 74 b. The positioning tabs 164 slidevertically in channels 74 a, 74 b until the top of the adaptor 160 is atthe desired height and then the adaptor 160 is rotated about axis 21 tofit the positioning tabs 164 into the desired space between the sets ofridges 70, 72 on the outside of the inner tubular sleeve 60. Thisarrangement allows a larger diameter than the inner tubular sleeve 60 tobe attached to the inner tubular sleeve 60.

As seen in FIGS. 15-16 , the adapter 160 may be inverted so that theexternal adapter threads 162 engage the internal threads 108 on the topend of the outer tubular sleeve 98. In this orientation, the adapter 160provides a larger diameter sleeve on the end of the outer sleeve 98. Theadapter 160 has a fixed height, but the overall height of the extendablesleeve assembly 20 may be adjusted by adjusting the position of theouter sleeve 98 on the inner tubular sleeve 60.

Referring to FIGS. 11A-11B, an optional aerator box 170 bay bereleasably connected to the bottom of the lower base 26. The lower base26 has internal threads 27 (FIG. 3 ) which may threadingly engageexternal threads on the upper end of the aerator box 170. The aeratorbox 170 has an outwardly extending flange 172 with optional fastenerholes in the flange. Fasteners may connect the aerator box 170 to aconcrete form to position the intumescent ring 34 further into thethickness of the concrete structure, and to allow an enlarged recess orcavity on what is typically the lower surface of the concrete structure.The general configuration of the aerator box 170 may be cylindrical orit may have various flat sided shapes, or combinations of curved andflat sides.

Referring to FIGS. 21A-21C, the CD plate may have various upwardextending projections 180 each fitting into a different one of pluralslots 182 in the lower base 26 in order to interconnect the CD plate 22and lower base 26. The projections 180 are preferably upwardly bentportions of a metal CD plate 22 or molded projections of a plastic CDplate and restrain relative lateral movement and rotation in the planeof the CD plate between the lower base 26 and the CD plate 22. Otherconnections could be used, including threaded fasteners to interconnectthe parts.

There is advantageously provided a method of forming a fluid passagethrough a concrete structure poured onto a support using an extendablesleeve assembly 20 and to self-support a floor fitting 140 with a flange144 at the finished concrete surface using the extendable sleeveassembly 20 and a no-hub connector 146. The lower base is fastened tothe upper base and seal assembly 36 by snap lock fittings and thenfastened to the support onto which the concrete is poured. If thatsupport is a corrugated deck that the lower base 26 is snap fit to CDplate 22. If that support is the typical plywood support than fastenersare passed through fastener holes in the lower base 26, where thefasteners typically comprise threaded fasteners or nails. The sleevetubular 60 may be snap-fit to the upper base and seal assembly 36 beforeafter the lower base 26 is connected to the support onto which theconcrete is poured. As needed, an outer sleeve 98 or an adapter 160 isconnected to the base or the inner tubular sleeve 60, advantageouslyusing threaded connections or threaded fasteners as described herein.Advantageously, threaded fasteners pass through aligned sockets 28, 46,29 and into or CD plate 22 or the support onto which concrete is poured.A cap 102, 120 is placed over the open end of the extendable sleeveassembly 20. The height of the inner tubular sleeve 60 or 98 is adjustedto the desired height, the vertical alignment of axis 21 is checked andthe parts adjusted as needed—although only small adjustments are needed.One or more wedges may be inserted between the base and support or theCD plate and the support to adjust the orientation of axis 21. The capmay be added before or after the height adjustment. The whisker assembly81 is likewise connected to the cap sometime before concrete is poured.After verifying alignment to the extent needed (not all concretestructures require the same alignment), the concrete is poured, theconcrete surface finished and the concrete structure is allowed to cureenough to walk on, preferably without marking the surface permanently.The whiskers identify the location of the cap, which is usually flushwith the concrete surface or slightly below the concrete surface. Thecap is removed, typically by pushing it upward and off by inserting apipe from below and through the extendable sleeve assembly 20.

If a drain fitting 140 is used, then the assembly 22 is as above, it thecap 102, 120 are omitted and a different cap, shaped to connect to andextend over and cover the parts of the drain fitting which are to beexposed after the concrete is finished. The floor fitting cover is notdescribed in detail but such covers are known in the art. The abovemethod adds a no-hub coupling 146 to the top end of the extendablesleeve assembly 20, whether that top end is formed by the inner tubularsleeve 60, the outer sleeve 98, or the adapter 160. The bottom end ofthe tubular body 150 fits over the top end of the sleeve, 60 or 98 orfits over the adapter 160 while the top end of the tubular body 150 fitsover the floor fitting tube or spigot 142, and the ring clamps 148 aretightened. The floor fitting 140 may be connected to the no-hubconnector 146 before or after connector 146 is connected to theextendable sleeve assembly 20. As the ring clamps 198 are tightenedheight, location and orientation of the floor fitting 140 and its topflange 144 are checked and adjusted as needed, with the ring clamps 148tightened to hold the floor fitting and its flange in the desiredposition. No wires, support struts or brackets are believed needed tomaintain the position of the floor fitting 140 and its top flange 144.Depending on the activity around the assembly or how long it has beensince the assembly was aligned, the position of the floor fitting andits top flange may be rechecked shortly before concrete is poured.Concrete is then poured, finished and the concrete structure cured untilit can be walked on without permanent deformation of the surface. Thecover over the floor fitting 140 is then removed, either from theexterior, finished surface of the concrete or by pushing a rod throughthe extendable sleeve assembly 20, no-hub fitting 146 and floor fitting140. When the floor fitting 140 is connected to the extendable sleeveassembly 20, it is preferred to have threaded fasteners pass throughaligned sockets 28, 46, 29 and into or CD plate 22 and/or into thesupport onto which concrete is poured to connect the parts to thesupport.

The various parts of the extendable sleeve assembly 20, the no-hubcoupling 146 and even the floor fitting 140 may all be included in akit, or any subset of these parts may be included in a kit.

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the present invention in virtually anyappropriately detailed structure.

The above description is given by way of example, and not limitation.Given the above disclosure, one skilled in the art could devisevariations that are within the scope and spirit of the invention,including various ways of configuring the latch members and catches thathold the parts together. Further, the various features of this inventioncan be used alone, or in varying combinations with each other and arenot intended to be limited to the specific combination described herein.Thus, the invention is not to be limited by the illustrated embodiments.

What is claimed is:
 1. An assembly for a concrete structure, comprising:a tubular sleeve having a cylindrical wall extending along alongitudinal axis for forming a passage through the concrete structure,the tubular sleeve having a plurality of radially extending ridgesseparated into segments with a channel parallel to the longitudinal axisseparating each segment, the channel having a circumferential width W,the ridges spaced apart a predetermined distance Z along thelongitudinal axis, the tubular sleeve having an inner diameter D; a capincluding a flange depending from and encircling a circular outerperiphery of the cap, the flange having a bottom end, and the cap havinga generally flat top surface; and at least one positioning tab extendinginwardly from the bottom end of the flange, the at least one positioningtab having a bottom surface that is orthogonal to the longitudinal axiswhen the cap is fastened to the tubular sleeve, the at least onepositioning tab having an inner surface that is inclined at an acuteangle to the bottom surface so the inner surface faces toward anunderside of the cap and toward the longitudinal axis, the at least onepositioning tab having a width in a circumferential direction whichwidth is smaller than the circumferential width W and having an axiallength which length is smaller than the predetermined distance Z, whenthe cap is fastened to the tubular sleeve, the at least one positioningtab may fit between two ridges of the tubular sleeve and slide axiallyoff any ridge engaged by the inclined inner surface.
 2. The assembly ofclaim 1, wherein the width is about the circumferential width W and thelength is about the predetermined distance Z.
 3. The assembly of claim2, wherein there are between two and six positioning tabs equally spacedabout a circumference of the flange.
 4. The assembly of claim 2, furthercomprising an inner, depending cylindrical flange having an outerdiameter about the inner diameter D but smaller than the inner diameterD.
 5. The assembly of claim 1, further comprising an inner, dependingcylindrical flange having an outer diameter about the inner diameter Dbut smaller than the inner diameter D.
 6. The assembly of claim 1,wherein the flange has a curvature that follows the circular outerperiphery of the cap.
 7. The assembly of claim 6, wherein the at leastone positioning tab is curved and has the same curvature as the flange.8. The assembly of claim 1, wherein the flange is 0.5 inch to 1-inchlong.
 9. The assembly of claim 1, wherein the flange is from 0.1 to 0.5times a length of the tubular sleeve.
 10. The cap of claim 1, whereinthe top surface of the cap includes a plurality of wrenching recesses.11. The cap of claim 10, wherein the top surface of the cap includes afemale whisker connector, and wherein the plurality of wrenchingrecesses are arranged around the female whisker connector.
 12. Anassembly for a concrete structure, comprising: a tubular sleeve having acylindrical wall extending along a longitudinal axis for forming apassage through the concrete structure, the tubular sleeve having aplurality of radially extending ridges separated into segments with achannel parallel to the longitudinal axis separating each segment, thechannel having a circumferential width W, the ridges spaced apart apredetermined distance Z along the longitudinal axis, the tubular sleevehaving an inner diameter D; the cap including a flange depending fromand encircling a circular outer periphery of the cap, the flange havinga bottom end, and the cap having a generally flat top surface; and atleast one positioning tab extending inwardly from the bottom end of theflange, the at least one positioning tab having a bottom surface that isorthogonal to the longitudinal axis when the cap is fastened to thetubular sleeve, the at least one positioning tab having an inner surfacethat faces toward an underside of the cap and toward the longitudinalaxis, the at least one positioning tab having a width ina-circumferential direction which width is smaller than thecircumferential width W and having an axial length which length issmaller than the predetermined distance Z.
 13. The assembly of claim 12,wherein the flange has a curvature that follows the periphery of thecap.
 14. The assembly of claim 13, wherein the plurality of positioningtabs are curved and have the same curvature as the flange.
 15. Theassembly of claim 12, wherein the flange is 0.5 inch to 1-inch long. 16.The assembly of claim 12, wherein the flange is from 0.1 to 0.5 times alength of the tubular sleeve.